Blind and shade cutting center for cutting two different window covering products

ABSTRACT

A sizing center for and a method of sizing different styles of window coverings includes at least two sizing mechanisms disposed on a sizing center in which each sizing mechanism is adapted to size a different style of window covering. Each window covering includes a color marking. At least two measuring scales are disposed on the sizing center, each measuring scale being associated with a sizing mechanism and having a different color, and each color associated with a sizing center being associated with a color marking of a window covering.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a divisional application of and claimspriority to U.S. Ser. No. 09/911,292, filed on Jul. 23, 2001, now U.S.Pat. No. *,***,***.

FIELD OF THE DISCLOSURE

[0002] The present invention relates generally to the field of windowcovering sizing machines and more particularly to a blind and shadecutting center.

BACKGROUND OF THE DISCLOSURE

[0003] Mass retail merchandisers sell a large number of window coveringsdirectly to consumers. Standard sized window coverings are sized to aconsumer's specifications while the consumer waits. The apparatusemployed to size the various window coverings must be both easy to useby an employee of a retail outlet and should not require an extensivetraining period.

[0004] Additionally, the floor space that the cutting apparatus requiresshould fit within the existing structure and layout of the retailoutlet. Further, the cutting apparatus ideally should size a number ofdifferent types of window coverings, such as metal or vinyl mini-blinds,vertical blinds, pleated shades, and cellular shades.

[0005] Many attempts have been made to integrate various window coveringcutting mechanisms into a single multi-station system. One example of amulti-station system is disclosed in U.S. Pat. No. 5,456,149 toElsenheimer et al. entitled “Sizing System for Window Coverings” issuedOct. 10, 1995. The '149 Patent discloses a station having a flip-topsurface including a pleated shade sizing station on one side and amini-blind sizing station on the other. This system minimizes the spacerequired by the merchandiser to cut various window covering products.This allows the retail outlet to include other stock and products inspace otherwise occupied by various window covering sizing equipment.

[0006] Recently, more retail merchandisers utilize 8-foot bay spacing todisplay and sell products. Accordingly, a shade and blind cutting centerthat can be located within the 8-foot bay environment is needed.

[0007] The sale of vertical blind products has also increased throughmass merchandiser retail outlets, requiring the ability to size not onlythe width of the vertical blind head rail but also the length of thevertical blind slats. However, if a cutting apparatus is to be locatedwithin an 8-foot bay environment, any vertical blind slat extendinggreater than 8 feet would not be able to be sized with an apparatuslocated within the 8-foot bay. Accordingly, there is a need for avertical blind cutting apparatus that would fit within the 8-foot bayenvironment as well as be able to size vertical blind slat producthaving a length greater than 8 feet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The invention will become more fully understood from thefollowing detailed description, taken in conjunction with theaccompanying drawings.

[0009]FIG. 1 is a perspective view of the apparatus located in a bay ina stored position.

[0010]FIG. 2 is a perspective view of the cutting apparatus of FIG. 1 inan operating position.

[0011]FIG. 3 is a cross-sectional view of the apparatus taken generallyalong lines 3-3 of FIG. 1.

[0012]FIG. 4 is a top plan view of the apparatus of FIG. 2.

[0013]FIG. 5 is a top partial view of the area taken generally alonglines 5-5 of FIG. 4.

[0014]FIG. 6 is a cross-sectional view of the locator pin takengenerally along lines 6-6 of FIG. 5.

[0015]FIG. 7 is a cross-sectional view of the die assembly of the firstcutting station taken generally along lines 7-7 of FIG. 4.

[0016]FIG. 8 is a cross-sectional view of the die and blade mechanism ofthe first cutting apparatus taken generally along lines 8-8 of FIG. 4.

[0017]FIG. 9 is the die and blade portion of the first cutting apparatusof FIG. 8 in the fully extended cutting position.

[0018]FIG. 10 is a cross-sectional view of the blade and die apparatusof FIG. 8 taken generally along lines 10-10 of FIG. 8.

[0019]FIG. 11 is a cross-sectional view of the cutting mechanism takengenerally along lines 11-11 of FIG. 8.

[0020]FIG. 12 is a cross-sectional view of the second cutting stationtaken generally along lines 12-12 of FIG. 4.

[0021]FIG. 13 is a view of the head rail cutting mechanism with the diein the raised position.

[0022]FIG. 14 is a view of the head rail cutting mechanism die cutter inthe raised position with the punch mechanism fully extended.

[0023]FIG. 15 is a cross-sectional view of the cutting apparatus takengenerally along lines 15-15 of FIG. 12.

[0024]FIG. 16 is a cross-sectional view of the cutting mechanism takengenerally along lines 16-16 of FIG. 12 in the extended cutting position.

[0025]FIG. 17 is a cross-sectional view of the apparatus taken generallyalong lines 17-17 of FIG. 4.

[0026]FIG. 18 is a partial cross-sectional view of the first cuttingstation in the lower position.

[0027]FIG. 19 is a cross-sectional view taken generally along lines of19-19 of FIG. 18.

[0028]FIG. 20 is an exploded perspective view of three locators, railand scale.

[0029]FIG. 21 is a cross-sectional view of the apparatus of FIG. 20.

[0030]FIG. 22 is an exploded perspective view of the connector clip andhead rail aperture.

[0031]FIG. 23 is an exploded perspective view of the connector clip ofFIG. 22 attached to the head rail aperture, and a portion of thelocator.

[0032]FIG. 24 is a top partial view of the head rail and connector clippositioned by the locator.

[0033]FIG. 25 is a top plan view of the cellular blind head rail andbottom rail positioned in the first cutting station of FIG. 7.

[0034]FIG. 26 is a top plan view of the cellular blind shade materialpositioned in the first cutting station of FIG. 7.

[0035]FIG. 27 is a cross-sectional view of the measuring deviceextension.

[0036]FIG. 28 is a perspective view of the vertical slat clamp andwooden blind clamp.

[0037]FIG. 29 is a partial side view of the wooden blind clamp. FIG. 30is a partial cross-sectional view of the vertical slat clamp.

DETAILED DESCRIPTION

[0038] Referring now to the drawings, an apparatus for sizing bothblinds and shades for window coverings is generally illustrated inFIG. 1. The blind and shade cutting center 10 is slidably movable onrails 12 in and out of a bay 14. The cutting center 10 includes a firstcutting station 16 for sizing mini-blinds, pleated shades, and cellularshades. The cutting center further includes a second cutting station 18for sizing wooden blinds and vertical blinds. The first and secondcutting stations 16, 18 are supported by and located on opposing ends ofa housing 20. A controller mechanism 22 allows an operator to gainaccess and to control the first and second cutting stations 16, 18.Further, cutting center 10 includes a center locating and measuringsystem 24 to position the blinds and shades to be sized.

[0039] Referring to FIGS. 2 and 17 the housing 20 of the cutting center10 includes a bottom 26, a front wall 28, a first and second side wall30, 32, a rear wall 34, and a top working surface 36. For purposes ofthis application the cross housing direction is defined as the directionthat is perpendicular to the front wall 28 and rear wall 34. Similarly,the longitudinal direction will be defined as the direction that isperpendicular to the first and second side walls 30, 32. The right sideof the housing 20 will be defined from the perspective of an operator asthey face the bay 14. Accordingly, the first side wall 30 is on theright side of the housing, while the second side wall 32 is on the leftside of the housing. The longitudinal axis of the housing will bedefined as an axis extending centrally on the top working surface 36 andperpendicular to the first and second side walls 30, 32. The crosscenter axis will be defined as an axis extending centrally on the topworking surface 36 and parallel with the cross housing direction. Thecross center axis is perpendicular to the longitudinal axis.

[0040] Housing 20 may be moved from a stored position (as illustrated inFIG. 1) in which the housing 20 is located within the bay 14 to anoperating position (as illustrated in FIG. 2) in which the housing 20 islocated substantially outside of the bay 14. The stored position permitsthe housing to be completely out of the aisle of a retail or massmerchandising outlet. In the operating position, the housing isaccessible for an operator to size a blind or shade product as will bedescribed below. While it is possible to size a blind or shade productwhile the housing is in the stored position, the length of the productto be sized may be limited by the size of the bay.

[0041] The bay 14 typically includes a front surface 28 and a first andsecond side support 40, 42. The supports 40, 42 may be in the form of awall or may be in the form of a frame. When the housing 20 is in thestored position, the front wall 28 may be flush with the front surface38 of the bay or may be located a distance within the bay from the aisleto ensure that no part of the cutting center 10 protrudes into theaisle. Further, if the cutting center 10 is completely located withinthe bay 14, the possibility of being damaged by a forklift or customercarts is minimized.

[0042] Housing 20 may include a handle or handles (not depicted) tofacilitate sliding the cutting center 10 in and out of the bay 14 on therails 12. All of the equipment employed in center 10 is attached to thehousing 20. The only portion of the center 10 that extends outward fromthe housing 20 is a vacuum bag 44 of a vacuum 46 (See FIG. 3). The depthof the housing 20 as measured in the cross housing direction is lessthan the depth of the bay 14. This permits the vacuum bag 44 to besituated behind the housing 20 when the center 10 is in the storedposition. Of course the vacuum bag 44 could also be stored inside of thehousing 20 and accessed through the rear wall 34 by an access means suchas a door.

[0043] As will be described below, the preferred embodiment includes acenter locating and measuring system as well as an end locating andmeasuring system. Both systems allow the operator to size a blind orshade by referring to only the customer's specification of the finalsize and length of the blind. In contrast, other sizing methods requiredthe operator to calculate the amount of material to be removed from eachside of the blind and to locate the blind relative to the sizing stationaccordingly. This may lead to errors in the final product, resulting inboth scrap material as well as a delay in the time it takes to deliver afinal sized product to the consumer.

[0044] The center locating system positively locates the center of theblind to be sized, while the end locating system locates the shaderelative to one end of the shade. Where the lift cords are visible tothe consumer such as in a Venetian blind or a pleated shade it isimportant that the lift cords remain symmetrical about the center of theblind. The center locating system employs a half scale that permits anemployee to size the blind by referring to only the customer's finalwidth of the blind. In contrast, the end locating system may be used forcellular shades where the lift cords are hidden from view and it doesnot matter that the lift cords are not symmetric about the center of theshade. Similarly, the end locating system may be used for a verticalblind head rail and vanes where the products may be sized from a singleend.

[0045] Referring to FIGS. 4 and 20, the pin locator 48, the center cliplocator 50, and the end locator 52 are illustrated. Each locator 48, 50,52 is attached to a respective carriage 54 having a plurality of rollers56 that are slidably received in a rail 58. The rail 58 extendsproximate the front wall 28 of the housing 20 and parallel to thelongitudinal axis of the housing 20. The rail 58 and carriage 54 deviceis available commercially and marketed under the trade mark Redi Rail™.The pin locator 48 and the center clip locator 50 illustrated in FIG. 20are center locating devices that positively locate the center of theblind or shade to be sized. The end locator 52 is a locating device thatis used to both square the blind or shade and to locate certain blindand shade products relative to one end of the blind.

[0046] The pin locator 48 and the center clip locator 50 both permit ablind to be sized from its center by engaging a center portion of theblind. The pin locator 48 includes an extension member 60 attached tothe carriage. A pointer 68 is attached to the carriage 54 and indicatesthe position of the pin locator 48 relative to the first or secondcutting stations 16, 18 by use of a scale as discussed below. Theextension 60 extends in the cross housing direction from the carriage 54toward the rear of the top working surface 36. A first pin 62 extendsfrom the carriage 54 parallel with the top working surface 36 of thehousing 20 and towards the rear wall 34. The first pin 62 is located apredetermined distance above the top working surface 36. A second pin 64may extend from the rear portion 66 of the extension 60 toward the frontwall 28 a predetermined distance above the top working surface 36.

[0047] Pins 62 and 64 each have a cross section that corresponds to thecross section of an aperture in the bottom rail of the shade or blind.In the example illustrated in FIG. 6, the pin 62 has a cross shapedcross section. However, any other shape may be employed as well, forexample a round cross section may be used. Pin locator 48 includes apointer 68 that identifies the location of the pins 62, 64 relative tothe first scale 70.

[0048] The center clip locator 50 is illustrated in FIGS. 4 and 20. Thecenter clip locator 50 includes an extension 72 attached to the carriage54 for slidable movement in the rail 58. A pointer 74 is attached to thecenter clip locator 50 that identifies the position of the locatorrelative to a second scale 76. The extension 72 of the center cliplocator 50 includes a slot 78 having a width configured to receive andpositively locate a center clip 80 attached to the center portion of theblind head rail or bottom rail (See FIG. 22.).

[0049] Referring to FIGS. 22 and 23, the center clip 80 is positivelysecured to a head rail 82 or bottom rail by positive location of aprotrusion 84 of the center clip with an aperture 86 or other locatingdevice in the center of head rail 82. Alternatively, the center clip 80could include an aperture that is positioned relative to a detent or tablocated on the head rail. Further, any other mechanical means oflocating the center clip 80 onto the head rail may be employed. In thepreferred embodiment the center clip 80 is made of a resilient materialsuch that the center clip 80 may simply be located in the center of theblind head rail prior to sizing and maintained in place by the springforce of the center clip 80.

[0050] As illustrated in FIG. 4, the pin locator 48 is positioned on theright side of the cutting center 10 and the center clip locator 50 ispositioned on the left side of the cutting center 10. However, thisorientation is for illustration purposes only. It is possible thatcutting center 10 includes two pin locators 48 on both the right andleft sides of the cutting center or two center clip locators 50 on boththe right and left sides of the cutting center 10. Any combination oflocators 48, 50 may be employed depending on the type of locating systemthat is used to locate the actual products to be sized.

[0051] The pin locator 48 as illustrated in FIG. 4 is slidablypositioned relative to a cutting plane 88 (See FIGS. 10 and 11) of thefirst cutting station 16 by the first scale 70. The first scale 70 islocated on the right side of a raised portion 90 proximate the rail 58(FIG. 20). Similarly, the center clip locator 50 is slidably positionedrelative to the cutting plane 92 (See FIG. 15) of the second cuttingstation 18 by the second scale 76.

[0052] The first and second scales 70, 76 each include half scaleindicia and extend proximate the front edge of the top working surfaceand parallel to the longitudinal axis. The first and second scales 70,76 include half scale indicia where each unit of measurement isidentified as twice its actual distance from the cutting planes of thefirst and second cutting stations respectively. For example, a distanceof fifteen inches (15″) from the cutting plane 88 of the first cuttingstation 16 is identified as thirty inches (30″) on the half scaleindicia.

[0053] The half scale indicia allows an employee or operator to size awindow blind by only knowing the final desired width of the windowblind. The width of the window blind is defined as the horizontaldistance between the two sides of the window blind when the window blindis installed relative to the window or opening to be covered. The heightof the window blind is the vertical distance that the window blind orshade covers. The term “length” as it is used in conjunction with theVenetian window blind head rail, slats or bottom rail will correspond tothe width of the window blind.

[0054] Referring to FIGS. 4 and 20, end locator 52 includes an extension94 attached to carriage 54 for translation along rail 58. Extension 94extends from the carriage 54 in the cross housing direction and includesa first side 96 and a second side 98 parallel to the first side 96. Thefirst side 96 faces the first cutting station 16 while the second side98 faces the second cutting station 18. As will be described below thefirst and second sides 96, 98 of the extension 94 extend a sufficientdistance from the top support surface 36 to engage the ends of the blindor shade to be sized to help align the head rail, bottom rail and windowcovering material for sizing. Further, the first side 96 is also used tolocate the cellular shade as will be described below. End locator 52further includes a set block 100 extending from the first side 96 a setdistance toward the first cutting station 16. The end locator furtherincludes a cut out region or a depression 102 in the top portion 94 ofthe extension 94 that permits a portion of the cellular window coveringmaterial of the cellular blind to extend through the extension 94 whenthe head rail and bottom rail are being sized. The end locator ispositioned between the right and left locators, which as illustrated inFIG. 4 is the pin locator and center clip locator respectively. Ofcourse, as noted above, the right and left locators may both be pinlocators or center lip locators.

[0055] Referring to FIGS. 7-10, first cutting station 16 will bedescribed in further detail. First cutting station 16 includes astationary die 104 and a moveable die 106 slidably coupled to thestationary die 104. A guiding die member 108 is secured to a first face110 of stationary die 104 to provide a plurality of beveled or flaredsurfaces 112 for guiding the various bottom rails, slats and head railsof the blinds and shades to be sized into openings in the stationary andmovable dies 104, 106.

[0056] Referring to FIG. 8, the stationary die 104 includes threeregions for cutting three different types of window covering products.The first region 114 is configured for sizing a mini-blind producthaving metal or aluminum slats and a metal head rail and bottom rail.This mini-blind product will be referred to as the metal mini-blindproduct. First region 114 of the stationary die 104 includes a firstchannel 116 for receiving a bottom rail of a mini-blind product, and anopening 118 for receiving a plurality of metal or aluminum slats fromthe metal mini-blind product. Further, first region 114 of stationarydie 104 also includes a second channel 120 for receiving the head railof the metal mini-blind product.

[0057] Additionally, stationary die 104 includes a second region 122 forsizing a mini-blind having a plurality of vinyl slats. This mini-blindconfiguration will be referred to as a vinyl mini-blind product. Thissecond region includes a channel 124 for receiving the bottom rail of avinyl mini-blind product having vinyl slats and a second opening 126 forreceiving the vinyl slats, and finally a third channel 128 for receivingthe head rail of the vinyl mini-blind product.

[0058] The third region 130 of stationary die 104 is for sizing apleated or cellular shade and includes a first pair of channels 132, 134for receiving the ends of a head rail and bottom rail from a pleated orcellular shade. Similarly, third region 130 may include a second pair ofchannels 136, 138 for receiving the second ends of the head rail andbottom rail from a pleated or cellular shade, when the head rail andbottom rail are not symmetric. However, in the preferred embodiment, thehead rail and bottom rail are symmetric and therefore only a single pairof channels is required. Accordingly, the second pair of channels 136,138 is shown in phantom lines. The third region 130 also includes anopening 140 for receiving the pleated or cellular material to be sized.

[0059] Referring to FIG. 9, the movable die 106 similarly has threeregions that correspond with the respective three regions of thestationary die 104. The first region 142 of the movable die 106 includesa first die opening 144 to receive both the portion of the bottom railand metal slats of the metal mini-blind to be sized. A first blade 146is attached to the movable die 106 and separates the first die opening144 from a second die opening 148 that receives the portion of the headrail to be sized. The first blade 146 is fastened to the movable die andincludes a cutting surface 150 that is proximate the stationary die 104.First blade 146 cuts both the metal slats and the bottom rail. Thegeometry of the first blade 146 permits the metal slats and bottom railto be sized with the same blade without the blade chipping when it cutsthe bottom rail member. First blade 146 has an arcuate surface thatcorresponds to an arcuate portion on the outer surface of the stationarydie 104. However, other known cutting shapes may also be employed.

[0060] The second region 152 of the movable die 106 is located below thefirst region 142. The second region 152 includes a first opening 154 toreceive both the portion of the bottom rail and vinyl slats of a vinylmini-blind to be sized. A second blade 156 is attached to the movabledie 106 and separates the first opening 154 from a second opening 158that receives the portion of the vinyl mini-blind head rail to be sized.The second blade 156 is fastened to the movable die 106 and includes asharpened edge 160 that is proximate the stationary die 104.

[0061] The third region 162 of the movable die 106 is situated in linewith the first region of the movable die such that it corresponds to thethird region 130 of the stationary die 104. The third region 162includes a first opening 164 and a second opening 166. A shearingportion 168 is located proximate the first opening 164 and a shearingportion 170 is located proximate the second opening 166. However, asingle opening and shearing portion may also be used.

[0062] Finally, the third region 162 of the movable die includes a thirdopening 172 for receiving the cellular or pleated shade material to besized. A blade 174 is attached to the movable die 106 and has a bladeedge 176 to cut the cellular and pleated material as the movable die 106is moved from a retracted position illustrated in FIG. 8 to the fullyextended position illustrated in FIG. 9.

[0063] As illustrated in FIGS. 17, 18a, and 18 b the stationary andmovable dies 104, 106 are attached to a frame 178 that is movable from afirst position in which the first regions 114, 142 and third regions130, 162 of the stationary and movable dies 104, 106 are proximate thetop working surface 36 of housing 20, to a second position in which thesecond regions 122, 152 are proximate the top working surface 36.Further the frame 178 may be moved to a third position in which theentire first cutting station 16 is lowered to a position below the topworking surface 36 to facilitate the sizing of vertical blind slatshaving a length greater than the width of the housing 20.

[0064] When the entire first cutting station 16 is lowered to a positionbelow the top working surface 36, an extension scale 180 may be attachedto the housing (See FIG. 27). A vertical peg 182 fastens the extensionto the housing 20 so that the extension scale 180 remains in a planeparallel with the top working surface 36. This feature allows a simpledisassembly upon raising the first cutting station 16 and also allowsthe extension scale 180 to slip out of its position on the housing ifthe first cutting station 16 is raised without first removing theextension scale 180. Further, if the housing is moved back into the baybefore removing the extension scale 180, the scale will simply pivotabout the peg 182 to prevent damage to the extension scale 180 or to thehousing.

[0065] In the preferred embodiment, the frame is moved between thefirst, second and third positions with a hydraulic piston 184 that iscontrolled by the controller 22. The hydraulic piston 184 is shown inFIGS. 17, 18a and 18 b.

[0066] In an alternative manual embodiment illustrated in FIG. 19 a pairof spring biased release mechanisms 186 is located on either side of theframe 178 to releasably secure the frame in the first, second or thirdpositions. Each release mechanism 186 includes a spring biased button188, each having a spring member 190 biasing a pin 192 into engagementwith one of three pairs of support members 194 attached to housing 20.By manually pulling the engaged pair of buttons 188 in an outwarddirection, the pins 192 are released from the support member 194 and theframe 178 may be moved upward or downward to another one of the pair ofsupport members. In this manner, the first cutting station 16 may bemoved manually between the first, second and third positions.

[0067] The method for sizing a metal mini-blind product utilizing thecutting center 10 will now be described in detail. As discussed above,cutting center 10 can cut more than one type of mini-blind or shadeproduct. The first cutting station 16 includes two different regions forcutting two different types of mini-blind products. The mini-blindproducts could have different geometry necessitating different dieopenings, and/or different shearing configurations, and/or differentblade combinations. In the example illustrated in the figures the firstcutting station 16 permits the sizing of two different mini-blindproducts formed of different material and having a different geometry.In the preferred embodiment, the first regions 114, 142 of thestationary and movable dies 104, 106 of the first cutting station 16 areconfigured to size a metal mini-blind product having a metal bottomrail, a metal head rail and aluminum slats. The second regions 122, 152are configured to size a vinyl mini-blind product having vinyl slats.

[0068] A customer will measure the width of the window or windows to becovered and bring this dimension to a retail outlet to purchase amini-blind product. If the mini-blind product in stock does not matchthe dimensions required by the customer, an employee/operator will sizea stock size mini-blind product to the customer's specified dimension.This system only requires that the operator select the stock mini-blindproduct having a width greater than that required by the customer. Theoperator, as will be described herein, does not need to calculate thedifference between the stock product and customer's dimensions, nor doesthe operator need to divide the difference between the stock mini-blindproduct and the customer's specifications. The operator will cut aportion of the head rail, bottom rail and window covering material fromeach end of the stock mini-blind product, without the need to know anyvalue but the customer's desired end width of the mini-blind. Byremoving material from both ends of the mini-blind product as describedbelow, each pair of lift cords will remain an equal distance from eachrespective end of the mini-blind.

[0069] Once the operator has identified and selected the stockmini-blind product closest to, yet wider than the customer'sspecification, the cutting center 10 is pulled from the stored positionin bay 14 as illustrated in FIG. 1 to the extended position asillustrated in FIG. 2. The operator gains access to the center controlsby entering a password into the center access panel 196 of the controlmechanism 22. The control mechanism 22 may be connected to a computerthat identifies the operator seeking access to the cutting center 10.The computer may also store the information entered by the operatorincluding the time of entry. The system may further be programmed toallow the operator to enter information relative to the stock blindbeing sized as a way of monitoring inventory. Additionally, the timerequired to size the mini-blind may be recorded. The access panel 196has the added benefit of prohibiting unauthorized personnel fromaccessing the cutting center 10.

[0070] After the cutting center 10 has been activated by means of theaccess panel 196, the operator loads the stock mini-blind product ontothe top working surface 36. As discussed above, both the pin locator andcentral clip locator for centrally locating the stock mini-blind to besized may be utilized. For illustration purposes only, the pin locatorwill be described-for locating the mini-blind product relative to thefirst cutting station 16 and the center clip locator will be describedfor locating the wooden mini-blind product relative to the secondcutting station 18. However, the center clip locator could be used tolocate the mini-blind product relative to the first cutting station aswell.

[0071] When using the pin locator, the bottom rail of each stockmini-blind product includes a centrally located aperture or openingthrough the bottom most portion of the bottom rail. The aperture couldalso be a slot extending perpendicular to the longitudinal axis of thebottom rail, or an indentation or depression or connector or any othermeans for centrally locating the mini-blind product. The aperture iscentrally located in the bottom rail, however, the aperture or locatingmeans could also be located in the head rail. The operator locates theaperture onto pin 62 of the pin locator 48. The portions of the firstend of the head rail, bottom rail and slats that are to be cut off areslid through the first regions 114, 142 of the stationary and movabledies 104, 106. The bottom rail is located in channel 116 of thestationary die 104 and opening 144 of the movable die 106. Similarly,the slats are located in opening 118 of the stationary die 104 andopening 144 of the movable die 106. Finally, the head rail is located inchannel 120 of the stationary die 104 and opening 164 of the movable die106.

[0072] The stock mini-blind product is positioned relative to thecutting plane 88 of the first cutting center 16 by lining up pointer 68of the pin locator 48 with the customer's specification on the halfscale indicia on first scale 70. The half scale indicia is dimensionedrelative to the cutting plane 88 of the first cutting station 16 whichis generally defined by the outer surface of the stationary die 104 thatdetermines the location of the sized end of the head rail, bottom railand slats after the movable-die 106 is activated and shears and/or cutsthe head rail, bottom rail and slats. The half scale units are one halfof the actual distance from the cutting plane. For example thirty (30)inches on the half scale is only one half of thirty (30) or actuallyonly fifteen (15) inches from the cutting plane. Once the movable die106 is activated the newly cut ends of head rail, bottom rail and slatswill be 15 inches from the center aperture.

[0073] To activate the movable die 106 in the first cutting station 16,the operator turns on the first cutting station 16 with an on/off switchlocated on the controller 22. By simultaneously depressing the toactivation buttons, the movable die 106 is moved from the rest positionto the extended position by a plunger 198 that is driven by a pneumaticor hydraulic cylinder 200. The first blade 146 shears the slats andsubsequently the bottom rail, while the shear portion of opening 148shears the head rail. If the operator releases the activation buttonsduring the cutting process, the movable die 106 will stop. This featureensures that the operator's hands are safely away from the movable die106 during the activation sequence. Once the movable die 106 is fullyextended and the first end of the head rail, bottom rail and slats aresized, the movable die 106 retracts to the rest position.

[0074] After the first side of the mini-blind product is sized, theoperator removes the mini-blind product from pin 62 and rotates it suchthat the sized end of the mini-blind product is away from the firstcutting station 16. The center aperture on the bottom rail of themini-blind product is once again located on pin 62. Once the mini-blindhas been located, the movable die 106 is activated and the second sideof the head rail, bottom rail and slats are sized. In this example thedesired width of the mini-blind product was thirty (30) inches. Sinceeach side of the blind was sized relative to the central locating holein the bottom rail, the cut ends of the mini-blind product are fifteen(15) inches from the center for a total mini-blind width of thirty (30)inches. In this manner the lift cords are equal distance from the centerof the mini-blind product and equal distance to their respective ends ofthe sized mini-blind product.

[0075] The sizing of the metal mini-blind occurs while the first cuttingstation 16 is in the first position relative to housing 20 as describedabove. A vinyl mini-blind is sized in a second position of the cuttingstation. To move the first cutting station 16 to the second positionutilizing the hydraulic piston, the operator utilizes the controller 22to move the first cutting station 16 to the second position. In thealternative embodiment, the manual release mechanism 185 may be used tomove the frame. The buttons 188 of the release mechanism are pulledoutward releasing the pins 192 from the support members 194 therebypermitting the operator to move the first cutting station 16 upwarduntil the buttons are aligned with and engaged with a second pair ofsupport members 194. The steps for sizing the vinyl mini-blind in thefirst cutting station are the same as the steps for sizing the metalmini-blind as described above. However, the vinyl mini-blind is sized inthe second regions 122, 152 of the stationary and movable dies 104, 106.

[0076] The process of sizing a pleated or cellular shade will now bedescribed. The pleated material is sized independently of the bottomrail and head rail. The shearing portions 168, 170 of the third portion162 of movable die 106 that are used to size the bottom rail and headrail of a pleated shade are not sharp enough to cleanly cut thematerial. The pleated material is sized in a separate step from thesizing of the head rail and bottom rail utilizing a sharp blade 174. Ina pleated blind the lift cords are visible and therefore it is desirableto have the pair of lift cords be symmetrical with respect to the centerof the pleated blind. Accordingly, the pleated blind may be sized infour distinct steps. First one end of the head rail and bottom rail aresized to the final width of the pleated shade. Second, one end of thepleated material is sized. Third, the other end of the head rail andbottom rail is sized. Fourth, the other end of the pleated material issized.

[0077] The steps for removing the cutting center 10 from the bay 14, andaccessing the cutting center 10 is the same as that described above forsizing the mini-blind products. Additionally, the first cutting station16 is moved to the first position to size the pleated shade product.This is the same position as when the metal mini-blind product is beingsized.

[0078] As with the mini-blind products discussed above, the bottom railof the pleated shade includes an aperture which is located on pin 64 ofpin locator 48. In contrast to the front pin 62 utilized to locate themini-blind products, the rear pin 64 is utilized to locate the pleatedor cellular shade. By using the half scale indicia of the first scale70, the pin locator 48 is aligned with the finished dimension of thecustomer's specification.

[0079] The first end of the head rail and bottom rail are slid intochannels 132, 134 respectively and openings 164, 166 of the movable die106. The pleated material however, is not slid into any opening at thistime, but rather the pleated material is slid relative to the bottomrail and head rail, so that one end of the pleated material extends pastthe second end of the head rail and bottom rail. The first cuttingstation 16 is activated as discussed above with respect to themini-blind products.

[0080] After the first ends of the pleated head rail and bottom rail aresized, the pleated material is slid into openings channels 132, 134 ofthe stationary die 104 and openings 164, 166 of the movable die 106. Thedimension of the guide die plate 108 proximate opening 140 does notpermit the head rail and bottom rails to pass into opening 140 and isstopped a predetermined distance from the cutting plane In the preferredembodiment, the distance from the ends is one inch. The end locator isused to size the pleated material. The end locator set block 100received between the, pleated shade bottom rail and head rail such thatthe set block 100 pushes the pleated material forward the sized end ofthe bottom rail and head rail a predetermined distance. In the preferredembodiment, the set block extends one inch from the first side of theend locator extension to compensate for the one inch distance the bottomrail and head rails are short of the cutting plane 88. In this mannerwhen the pleated material is sized by blade 174 the width of the pleatedmaterial is the same as the width of the head rail and bottom rail.

[0081] The process is repeated on the second ends of the pleated shadehead rail, bottom rail and pleated material. Where the head rail andbottom rail are not symmetric the second ends of the head rail andbottom rail will not fit in channels 132, 134. The second ends of thehead rail and bottom rail must be inserted into channels 136, 138respectively, that are configured to accommodate the differentorientation of the second ends of the pleated shade bottom rail and headrail.

[0082] Alternatively, the stock pleated shade product may be sized inthree steps. First the head rail and bottom rail may be sized by cuttingmaterial off from a single end to the final width of the customer'sspecification. Since the head rail and bottom rail are being sized fromone end only, a full scale may be utilized to locate the head rail andbottom rail relative to the cutting plane. The pleated material is thencut equally on both sides in two separate cutting operations so that thelift cords remain symmetric about the center of the head rail and bottomrail.

[0083] Referring to FIGS. 25 and 26, the sizing of the cellular productin two steps is illustrated. In the first step the entire portion to beremoved from the stock cellular head rail and bottom rail is removed ina single operation of the movable die 106 (FIG. 8). Accordingly, thecellular shade may be located relative to a cellular scale 202 havingfull scale indicia such that the markings on the scale 202 (FIG. 4)reflects the actual distance from the cutting plane 88. The end locator52 is utilized to locate the cellular product to be sized. The head railand bottom rail of the cellular product are inserted into channels 132,134 (FIG. 8) while the other ends of the head rail and bottom rail thatare not to be sized are located against the first side of the endlocator 52. The first side of the end locator 52 is aligned with thefull scale indicia of scale 202 corresponding to the actual width of theblind as requested by the customer. When the head rail and bottom railare being sized the cellular material is slid away from the ends of theblind to be cut off and towards the second cutting station 18. Thecellular material is allowed to pass through end locator 52 extension 94via opening 102.

[0084] Once the head rail and bottom rail have been cut to size, thecellular material is slid past the newly cut ends of the head rail andbottom rail into openings 140 and 172 of the stationary and movable dies104, 106 (FIGS. 8, 9) respectively. The end locator set block 100 pushesthe cellular material the required distance into the first cuttingstation to ensure that the cellular material will have the same width asthe head rail and bottom rail once it is sized. The set block 100 isutilized the same way for the cellular material as for the pleatedmaterial discussed above.

[0085] Referring to FIGS. 12-16 the second cutting station 18 includes avertical head rail shearing mechanism 204 and a wooden blind sizingmechanism 206. Vertical shearing mechanism 204 includes a stationary die208 having a channel 210 for receiving a head rail of a vertical blindproduct. The stationary die 208 includes a second opening 211 forreceiving the traverse rod of the vertical blind product. A movable die212 moves relative to the stationary die 208 in a vertical up/downdirection. Movable die 212 includes a shearing portion 214.Additionally, vertical shearing mechanism 204 includes a punch 216 thatpunches a hole in the base of the vertical blind head rail a setdistance from the cut end of the head rail as described below. Avertically oriented piston 217 moves the movable die 212 upward anddownward as illustrated in FIGS. 13 and 14 respectively.

[0086] Turning to FIGS. 12, 15 and 16, the wooden blind sizing mechanism206 includes a circular saw 218 having a circular blade 220 that movesfrom a first position proximate the rear wall 34 to an extended positionin the cross housing direction toward the front wall 28.

[0087] The sizing of a wooden blind having a metal head rail, a woodenbottom rail and wooden slats will now be described. While a pin locator48 could be used to locate the wooden blind for sizing, the center cliplocator 50 will be described in connection with the sizing of the woodenblind. As illustrated in FIGS. 22 and 23, a head rail includes anopening 86 that receives a protrusion or tab extending from clip 80. Inthis manner the clip is positively located on the center of the headrail 82. The clip 80 is then positioned within slot 78 of the centerclip locator 50, which positions the clip and the head rail relative tothe second half scale 76. A pointer 74 on the center clip locatoridentifies the center position of the wooden blind to be sized relativeto the cutting plane 92 of the circular saw 218.

[0088] Once the head rail and clip are located within the slot of thecenter clip locator, the wooden blind bottom rail, slats and head railare slid into a first opening 221 in the second cutting station (SeeFIG. 28). The wooden blind is located by moving the center clip locator50 to align the pointer 74 of the center slat locator with thecustomer's width specification on the second scale 76.

[0089] Once the wooden mini-blind is at the proper location to be sized,the end locator 52 is used to square the ends of the head rail, slatsand bottom rail, by using the second side extension second side 98. Aclamp mechanism 222 clamps the bottom rail, the wooden slats and thehead rail against a stop 224 (See FIG. 29) such that the sides of therails and slats are parallel to the top working surface 36. This removesany space distance between the slats, the bottom rail and the head rail.

[0090] Once the bottom rail, slats and head rail have been locatedwithin the opening 221 and clamped against the stop 224, the first endof the wooden mini-blind is ready to be sized. As with the first cuttingstation 16, the operator first enters the access code in the centeraccess panel 22 to allow activation of the second cutting station 18. Toactivate the sequence for sizing the wooden blind bottom rail, slats andmetal head rail, the operator turns on the second cutting station 18with the on/off switch. By simultaneously depressing two activationbuttons, the following sequence is activated. First the vacuum 46 isstarted and the circular saw 218 is activated and moved toward the frontwall 28 along cutting plane 92 cutting the bottom rail, slats and headrail until the bottom rail, all of the slats, and the head rail are eachsized. The circular saw 218 is then moved rearward until it is in itsfully withdrawn position. In the preferred embodiment the movement ofthe saw is automated and controlled by the controller 22.

[0091] In addition to wooden slats, the circular saw 218 may also sizefaux wood slats made of a cellulose plastic formulation or of slats madefrom a plastic material, or any other type of material that caneffectively be sized with a circular saw. The circular saw 218 includesa circular saw blade 220 that travels along a cutting path 92.

[0092] It is also possible to size a valance for the wooden blind at thesame time the head rail, bottom rail and slats are being sized. Thevalance is simply located adjacent the head rail or bottom rail andsized along with the other components.

[0093] A vertical blind may also be sized in the second cutting station18. A vertical blind head rail is sized in the vertical shearingmechanism 204 by locating the vertical blind head rail in the verticalblind head rail channel 210. The vertical blind traverse rod is locatedwithin the traverse rod opening 211. Since the vertical blind; does notinclude lift cords, the vertical blind head rail may be sized byremoving material from a single side of the stock head rail.Accordingly, a scale 225 (FIG. 4) having full scale indicia are used todetermine the width of the vertical blind. Again, the width of thevertical blind is measured to correspond to the width of the window itwill be covering. The cutting plane of the vertical shearing mechanism204 is not in the same plane as the cutting plane 92 of the circularsaw. The vertical shearing mechanism is set inward in the housing topermit the circular saw to fully extend along its cutting plane 92without contacting the shearing mechanism. The scale 225 measures theactual distance to the cutting plane of the vertical shearing mechanism204.

[0094] The vertical shearing mechanism 204 also includes a punch 216 toplace an aperture in the base of the vertical head rail a set distancefrom the cutting plane of the vertical shearing mechanism 204. Theaperture is located a predetermined distance from the cut end of thehead rail to receive a portion of a snap-in end cap to be added to thevertical head rail once it has been sized. The aperture could also beused to receive a fastener such as a screw to secure an end cap to thehead rail. Punch 216 is pivotally connected to a lever 228 that ispivotally connected to the vertical shearing mechanism 204. The lever228 is pivotally connected to a head portion 230 of a rod 232 which isslidably located in a holder 234 attached to the movable die 212. Thehead portion 230 includes a base portion having a diameter larger thanthe rod 232 and larger than the opening in the holder 234.

[0095] The operation of the vertical shearing mechanism 204 for sizingthe vertical blind head rail will now be described. Since the verticalblind head rail can be sized by removing material on one side of thehead rail, no centering locating mechanism need be used. Rather, thevertical blind head rail can be measured by use of the full scaleindicia on scale 225. The end of the vertical blind head rail to be cutis placed in channel 210 and the traverse rod is placed in opening 211.The free end of the head rail that is not being sized is aligned withthe full scale indicia indicating the customer's specification for thedesired width of the vertical blind product. The vertical slats will besized to a different measurement, since the important feature of thevertical slats is their vertical length when they are placed over awindow. Once the vertical blind head rail and traverse rod are locatedin the stationary die 208 the operator activates the shearing mechanismby following the steps outlined above of inputting the access code,turning the on/off switch to the on position for the second machinecutter, and depressing the two activation buttons.

[0096] The movable die 212 will move in an upward direction until the“v” shaped shearing portion 214 contacts and shears the vertical headrail and the traverse rod. Once the holder contacts the base of the headportion 230, the head portion is moved upward, thereby causing the pivotof lever 228 about its pivot point and causing the punch 216 to extenddownwards through the head rail. In this manner, an opening is formed inthe vertical head rail a predetermined distance from the sheared end ofthe vertical head rail.

[0097] Once the movable die has reached its fully extended upwardposition and the head rail and traverse rod have been sheared and theopening has been punched in the head rail, the movable die is retracteddownward to the starting position. The vertical blind slats may also besized in the second cutting station 18 to a customer's specifications.The vertical slats extend in a vertical position and therefore arelikely to have a dimension different than the head rail width. Thevertical slats are clamped down onto top working surface 36 with avertical clamp 236 (See FIG. 30) such that the face of the verticalslats are parallel to the top working surface 36. If the vertical blindhead rail is longer than the space between the first and second cuttingstations 16, 18, the first cutting station 16 may be lowered to a thirdposition as discussed above to allow the vertical head rail to resthorizontally on the top working surface 36. When the first cuttingstation 16 is lowered to the third position, the top of the frame 178 issubstantially flush with or lower than the top working surface. Thescale extension 180 is located in housing 20 and extends the full scale226 (FIG. 4) that measures the actual distance to the cutting plane 92.

[0098] Unlike the wooden mini-blind product in which the bottom rail,slats and head rail are all positioned relative to the second cuttingstation together, the vertical head rail and vertical slats arepositioned and sized separately.

[0099] In another embodiment, each scale is used for sizing a specificblind or shade product. Further, each scale may have a separate distinctcolor that corresponds with the color of the packaging for respectiveblind or shade product to be sized. As a result, an operator will beable to determine which scale to use to size the stock blind or shadeproduct by matching the color of the stock blind or shade packaging withthe appropriate scale. The instructions that are located on the housingmay also be in color to further reduce the chance that the particularstock blind or shade product is sized incorrectly. Additionally, theinstructions that are located in an instruction manual may also be colorcoordinated with the scale and stock product packaging. Since the scale,packaging for the blind or shade product and instructions all share thesame color for sizing of a specific product, the chance of errordecreases, resulting in an easier process for the operator.

[0100] In a further embodiment, the locator pin may be eliminated. Theblind or shade product may include a mark or feature that is located onits longitudinal center. This mark or feature would be aligned with theappropriate marking on the appropriate scale as discussed above. Whilethe locator devices provide for a positive placement of the blind orshade product, it is possible to locate the center of the blind or shadeproduct by means of a mark such as a line placed on the product in thefactory before being shipped to the retain outlet. Of course the markcould also be placed by the operator in the retail outlet as well priorto sizing.

[0101] The stock blind or shade product would also have a feature suchas an indentation, groove or protrusion on the center of the blind thatcould be used to locate the stock blind or shade product relative to thescale.

[0102] While the detailed drawings, specific examples and particularformulations given describe exemplary embodiments, they serve thepurpose of illustration only. The systems shown and described are notlimited to the precise details and conditions disclosed. Furthermore,other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the exemplaryembodiments without departing from the scope of the invention asexpressed in the appended claims.

We claim:
 1. A method of sizing different styles of window coveringproducts on a sizing center, each style including a color marking, thesizing center including at least two sizing mechanisms, each sizingmechanism including an associated measuring scale, each scale having adifferent color, the method comprising: disposing a window covering onthe sizing center adjacent a scale with a color corresponding to thecolor marking of the window covering; measuring the window covering withthe scale; and sizing the window covering with the sizing mechanismassociated with the scale.
 2. The method of claim 1, wherein the sizingmechanism defines a cutting path, the method including disposing an endof the window covering across the cutting path.
 3. The method of claim2, wherein the sizing mechanism includes a saw, the method includingsizing the window covering by traversing the saw along the cutting path.4. The method of claim 2, wherein the sizing mechanism includes amovable die and a fixed die, the method including sizing the windowcovering by moving the movable die relative to the fixed die.
 5. Themethod of claim 4, wherein the sizing mechanism further includes apunch, the method including punching a hole in the window covering. 6.The method of claim 1, the sizing center including a carrier movablesubstantially perpendicular to the sizing mechanism, the methodincluding disposing the window covering on the carrier.
 7. The method ofclaim 6, further comprising moving the carrier and the window coveringsubstantially perpendicular to the sizing mechanism and relative to thescale until the desired length is found.
 8. The method of claim 7,wherein the scale includes half-scale indicia, the method includingmoving the carrier and window covering relative to the scale until thedesired full width of the window covering in indicated.
 9. The method ofclaim 8, the carrier including a pointer, the method including aligningthe pointer with the desired length indicated by the half-scale indicia.10. A sizing center for sizing different styles of window coverings,each window covering including a color marking, the apparatuscomprising: at least two sizing mechanisms disposed on the sizing centerand each sizing mechanism adapted to size a different style of windowcovering; at least two measuring scales disposed on the sizing center,each measuring scale being associated with a sizing mechanism and havinga different color; each color being associated with a color marking of awindow covering.
 11. The apparatus of claim 10, wherein a first sizingmechanism of the at least two sizing mechanisms is defined by a fixeddie and a movable die.
 12. The apparatus of claim 11, wherein the firstsizing mechanism includes a punch.
 13. The apparatus of claim 10,further comprising a fixed plate and a movable plate, the fixed plateincluding a first die for a first style and a second die for a secondstyle, the movable plate including a first die for a first style and asecond die for a second style, the first dies defining a first sizingmechanism and the second dies defining a second sizing mechanism. 14.The apparatus of claim 10, wherein a first sizing mechanism is definedby a circular saw.
 15. The apparatus of claim 10, wherein a firstmeasuring scale includes half-scale indicia.
 16. The apparatus of claim10, further comprising a slidable carrier, wherein the slidable carrierincludes a protrusion adapted to engage the window covering.
 17. Theapparatus of claim 16, wherein the carrier includes a pointer adapted topoint to a measuring scale.
 18. The apparatus of claim 10, wherein thesizing center has a left end and a right end, and a first sizingmechanism of the at least two sizing mechanisms is disposed on the rightend, and a second sizing mechanism of the at least two sizing mechanismsis disposed on the left end.
 19. The apparatus of claim 10, wherein thesizing center has a first end and a second end, and a first sizingmechanism of the at least two sizing mechanisms and a second sizingmechanism of the at least two sizing mechanisms are disposed on thefirst end.
 20. The apparatus of claim 10, further including instructionsfor sizing each different window covering in a color that corresponds tothe scale and marking on the respective covering products.
 21. A sizingcenter for sizing different styles of window coverings, each style ofwindow covering including a different color marking, the apparatuscomprising: at least two means for sizing window coverings disposed onthe sizing center and each sizing means adapted to size a differentstyle of window covering; at least two means for measuring windowcoverings disposed on the sizing center, each measuring means beingassociated with a sizing means and having a different color; each colorbeing associated with a color marking of a window covering.